The Fort Miller Co., Inc.
Precast Pavement Construction
Using The Super-Slab System ®
October 31, 2013
The Fort Miller Co., Inc.
Dan E. Moellman, P.E.
The Fort Miller Co., Inc.
• Located in upstate New York
• Transportation products
Highway barrier
Schuylerville, NY
Precast retaining walls
Bridges
Precast pavement slabs
• Specializing in accelerated bridge construction
• Developer and promulgator of the Super-Slab®
Precast Pavement System
The Fort Miller Co., Inc.
Precast Concrete Pavement Slabs =
Overnight Repairs
145,000 ADT
180,000 ADT
I-287, Tarrytown, NY
Cross Bronx Exp.
162,000 ADT
BrooklynBrooklyn-Queens Exp.
The Fort Miller Co., Inc.
Overnight repairs for
Failed Interstate Pavement!
Pavement
Shattered Slabs
Failed Rapid Set Patches
Heavily Faulted Slabs
Pasadena, CA
Hollywood, CA
Pasadena, CA
210 Freeway, Pasadena, CA
The Fort Miller Co., Inc.
Urban Arterial & Intersection
Pavement in Poor Condition
50 Year Old Pavement
Many Utilities
Poor Surface Drainage
Shoved Black Top
The Fort Miller Co., Inc.
Precast Pavement BASICS
Precast Slabs
+ Uniform Support
+ Match Road Surface
+ Effective Load Transfer Between Slabs
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Successful Long-term Repair
The Fort Miller Co., Inc.
Precast Pavement Emulates Cast in Place
•
•
•
•
Full Bedding Support
Load transfer Dowels
Grade Control
Slab Surface Geometry
The Fort Miller Co., Inc.
Overview of Current Precast Systems
• Precast Prestressed Concrete Pavement (PPCP)
Pre & post tensioned ( 250’+ assembly)
Developed by FHWA (non-proprietary)
• Top-Slot Jointed Systems (Michigan Method)
Jointed – slab lengths 16’ + long
Developed by FHWA (non-proprietary)
Flowable fill or urethane foam support
• Bottom-Slot Jointed System (Super-Slab®)
Jointed – slabs 6’ to16’
Grade supported
• Other systems are “appearing”
The Fort Miller Co., Inc.
Grade-Supported, Bottom-Slot
Super-Slab® System
• Simple slab-on-grade system
• Standard dowels and tie bars (JRCP)
• Built-in bedding grout distribution
• Precision grading equipment
• Warped and planar surfaces
• 15,000 + slabs = 1,575,000 SF INSTALLED
(78 projects, 27 lane-miles completed in 13 States + ONT & QUE)
The Fort Miller Co., Inc.
Controlled Fabrication Conditions
Accurate Forms
Accurate Piece Drawings
Roller Screed - Accurate Top Surface
Ideal Finishing (and curing)
Conditions
The Fort Miller Co., Inc.
Grade Control & Slab Support –
A Two - Step Process
Secondary Bedding
Primary Bedding
Grade control
rails placed to
survey marks
Precisely-Graded (to + 1/8”)
and Compacted Fine
Aggregate Material
Grout Distribution
Channel
Foam Gaskets
Proof
Bedding Grout Fills Any Voids
The Fort Miller Co., Inc.
SuperSuper-Slab®
Slab®
Load Transfer Dowel System
• Dowels engage slots in adjacent
slab
• Pump dowel group into ports
Grout reaches 2500 psi in about 2
hours
• Fill slots and joint between slabs
• Dove-tail slot resists bar pop out
Dove-tail-shaped slot
The Fort Miller Co., Inc.
Load Transfer Mechanisms
–BottomBottom-Slot SuperSuper-Slab®
Slab®
(proprietary detail)
•
“CLEAN” TOP OF SLAB
•
STRONG CONNECTION
•
FAST – SLOTS CAST IN
The Fort Miller Co., Inc.
Indicators for Long Life
Full scale load testing in California
Test results
show
no cracks or
distress
Falling Weight Deflectometer
Heavy vehicle simulator
143 Million ESALs (100 KN Load)
4.3 Million Cycles
The Fort Miller Co., Inc.
Slab Surface Geometry
Warped Plane
Single Plane
•
Slopes of opposite sides
are equal
•
Slopes of opposite sides
are un-equal
The Fort Miller Co., Inc.
At the Site
• Lay out slab locations and limits
• Cut and remove existing slabs
May be a single or a multiple of single slabs
• Install load transfer dowels and tie bars
• Place, grade and compact bedding material
Mainline or ramps
• Place slabs
At specified locations
• Install dowel and bedding grout
• Grind (if necessary) to achieve smoothness
requirements
The Fort Miller Co., Inc.
Saw Cutting and Removal
Cuts - Full Depth
- Accurate
Slab crab bucket
Trucks - right size
- right number
The Fort Miller Co., Inc.
Drilling for Dowels
Mark Out (accurately)
to Match Dovetail Slots
16 holes – 12 minutes
The Fort Miller Co., Inc.
Precision Grading is the Key!
Super-Grading = Grading to 1/8th inch +, fully compacted
• Thin layer (1/2”) fine bedding material
• Grade – Compact - Grade
• Provides “near complete” subgrade
support without grout
• Slabs can be opened to traffic before
grouting
Small Scale Grading
Rail Supported and Hand Operated
Auger H.O.G.
MiniMini-H.O.G.
Hand Operated Grader (H.O.G.)
Shutter Screed
The Fort Miller Co., Inc.
Grading Patches With HandOperated Grader (H.O.G.)
Three Steps
(12 minutes)
First Pass (high)
Compaction
Last Pass (done)
The Fort Miller Co., Inc.
Continuous Grading With
Hand Operated Grader H.O.G.
Three Steps
First Pass (1/4”
(1/4” high)
Last Pass (done)
Compaction
(over 500 LF per night possible)
The Fort Miller Co., Inc.
Drilling for Dowels
Mark Out (accurately)
to Match Dovetail Slots
16 holes – 12 minutes
The Fort Miller Co., Inc.
Shipping and Placing
•
Size slabs for shipping
12’ Max. width
Special permits
•
Ship in order – by mark
number
•
Provide unloading lane /
shoulder
The Fort Miller Co., Inc.
Placing Slabs – Continuous
Crane Occupies New Slabs
String Line
Set Slab to String
12’
12’ Lane & 10’
10’ Shoulder (min.)
The Fort Miller Co., Inc.
Placing Slabs – Intermittent
Center Slab in Hole
(Single Slab Holes)
Crane Occupies New Slab
The Fort Miller Co., Inc.
Grouting
•Truck
Truck (grout material &
water)
•Trailer
Trailer (grout mixer/pump)
•Short
Short hose & nozzle
•Pails
Pails (for water measuring)
•Barrels
Barrels (for waste)
Requires Grout Rig
(Typically completed subsequent nights)
The Fort Miller Co., Inc.
Installing Dowel Grout
Fill Dowel Slots and Joints First
ContractorContractor-Designed Joint Dam
The Fort Miller Co., Inc.
Installing Bedding Grout
PrePre-bagged Bedding Grout
Flow Rate
(Recommended)
15 - 20 Seconds Max.
Keep Ports Full by
“topping off”
off”
The Fort Miller Co., Inc.
NJDOT & NYSDOT Specifications
NJDOT Sec 453 – Full Depth Concrete Pavement
Repair, Precast
NYSDOT 704 -15 Precast Concrete Pavement
Slab Systems
• Fabrication Standard Drawings, Install Instructions, Trial Installation
• Approved List
NYSDOT EI 05-043 Precast Concrete Pavement
Slab Systems – Design Guidance
NYSDOT 502.15PF—18, Precast Concrete
Pavement Slabs
The Fort Miller Co., Inc.
Intermittent Repairs (CPR)
I- 90
Albany, NY
I-676 Vine St
Expressway
Philadelphia,
PA
I-15 Salt Lake
City, Utah
I-95, New Rochelle, NY
The Fort Miller Co., Inc.
Continuous Tappan Zee Bridge Toll Plaza
(Within + 1/8”
1/8”)
Open for Rush
Hour
2001 - 2002
(135,000 ADT)
3,000 SF / 8 Hour Shift
The Fort Miller Co., Inc.
Continuous - Mainline Placement
Mainline I-15, Ontario, CA
(200,000 VPD)
The Fort Miller Co., Inc.
Ramps
Chicago, Il
Brooklyn, NY
Plan View Tarrytown
Tarrytown, NY
The Fort Miller Co., Inc.
Intersections – Replacing Composite
Pavement, – Rotterdam, NY - 2006
New & Old
Undercuts
Complex Geometry
Replaced in 17 Nights!
NY 7 Crosstown Connection
The Fort Miller Co., Inc.
Intersection Approaches – Replacing
Full Depth Ashpalt,
Ashpalt,
Rockaway Blvd., Queens, NY – 2010
Farmers Blvd
Guy R. Brewer Blvd.
Intersection Approaches Only
The Fort Miller Co., Inc.
Bridge Approach Slabs
(Existing Bridges)
Binghamton, NY (2009)
Cross Section at Abutment
NY State DOT
The Fort Miller Co., Inc.
Bridge and Approach Slab
Total Replacement
US 46 Over Broad St., Clifton, NJ
• Bridge replaced over two
weekends - April 2011
Bridge Units
• Two-span (40.2’, 40.2’) continuous,
28.76° skew
• Precast Approach Slabs - tied to
prefabricated bridge units
Skewed Approach Slabs
The Fort Miller Co., Inc.
Bus Pad, Hollywood & Santa Monica Blvd.
North Hollywood, CA
Grading
Last Slab
Placing
Finished, Next Day
The Fort Miller Co., Inc.
Industrial Driveways
City of Mamaroneck, NY
Continuous Access During Construction
The Fort Miller Co., Inc.
Brooklyn Bridge Approaches
2010 – 2013
Grading
Placing
Looking Towards Manhattan
Looking Towards Brooklyn
The Fort Miller Co., Inc.
Alexander Hamilton Bridge
West Approach, 2011 – 2013
Grading
Lower Level
Contractor Gets One Lane
To Replace The Same Lane
Placing, June 2012
The Fort Miller Co., Inc.
Other Places for Fast-Track
Precast Pavement
• Under Bridges
• Instrumented pavement
Toll booth treadles
• Weigh and Motion Stations
• Round-Abouts
• Utility corridors
I-78 Interchange 14C Toll Plaza
NJ Turnpike Authority, Jersey City, NJ
The Fort Miller Co., Inc.
Intermittent - Installation Rates
• 8 hour work window
• 12 – 15 slabs (12’ x 10’) per night
• 5 hour work windows
7 – 9 slabs (12’ x 10’) per night
• Dependent on work window length
and spacing of repairs
The Fort Miller Co., Inc.
Continuous - Installation Rates
8 – 10 Slabs (1500 – 2000 SF) per
Hour
12’ x 14’ slabs
Average rate of over 6000 SF ( 500
Lane Ft.) per 8 hour shift – I-15,
Ontario, CA
• About one mile in two weeks
Rates should improve
As Contractors become more familiar
Improved specialized equipment
The Fort Miller Co., Inc.
Smoothness
•
Small differences are expected
Fabrication tolerance
Grading tolerance
•
Super-Slab® finished surfaces + 1/8”
May be acceptable for slow speed
traffic
•
Grind for best International
Roughness Index
Diamond Grinding is an accepted and
cost-effective practice
The Fort Miller Co., Inc.
Installed Costs (Bid Prices)
• Intermittent Repairs
About $ 238 to $ 450 per SY
Similar to rapid-set concrete costs (in some states)
• Continuous Installations
About $ 238 to $ 400 per SY
Up to 20% less than intermittent repair slabs
• Varies greatly with
Length of work window
Size of project
Local labor rates
The Fort Miller Co., Inc.
Compare with Conventional Fast-Track
Concrete Actual Bid Prices (NY State)
Item No.
Description
(SY)
502.2001
Saw Cutting
$ 23.33
502.3101
Lift Out Removal
$ 13.33
502.3301
Tie Bars
$ 30.00
502.3201
D & A Dowels
$ 30.00
502.3603
PCC Placement
$ 175 - $ 238
Total
$ 272 - $ 335
The Fort Miller Co., Inc.
Pavement - Asset Management
Strategies With Precast Available
• Use quality precast material every time
40-year service life
• Use maintenance dollars for good repairs, not temporary
ones
• Consider life cycle rather than first costs
• Rather than patching, consider “intermittent total
replacement”
Keep adding on to good precast repair slabs
• Consider “re-usable” precast pavement in utility-intensive
areas
The Fort Miller Co., Inc.
New Developments in Super-Slab
Precast Pavement
The Fort Miller Co., Inc.
Super-Dowel (Pat. Pending)
Removable & Replaceable
Enables Removable (& Replacable)
Precast Pavement
The Fort Miller Co., Inc.
Incremental Total Replacement
Using SuperSuper-Dowels
Makes The Most of Our Existing Concrete Pavement Asset
The Fort Miller Co., Inc.
Super-Paver – A Re-usable Urban
Pavement (RUP) System (Made
Possible With Super-Dowels)
•
Light weight
•
6’ x 6’ weighs 2 T
•
Vertically removable & replaceable
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Warped as required to fit any surface
•
•
Standard warps are in stock
Removable and reusable
(Designed specifically for utility-intensive urban highways
and intersections)
The Fort Miller Co., Inc.
Slab Removal & Replacement
Remove Slab Vertically and Clean
SuperSuper-Dowel
Utility Trench
Replacing CleanedCleaned-up Slab Over New Dowels
The Fort Miller Co., Inc.
Slab Layout Possibilities
• Remove slabs to work on
utilities (Super-Dowels)
• Clean up and replace
removed slabs
• Mix big and small SuperPavers as needed
SuperSuper-Pavers Installed Over Utilities
NYC DOT – Broadway Junction
Van Sinderen Avenue
The Fort Miller Co., Inc.
Reasons for Using Precast Pavement
• Heavy traffic
Requires most durable repair
Urban arterials most likely candidates
• Long term detours and staging not options
Access ramps, intersections prime candidates
• Traffic volumes require short work windows
If you have only 8 hrs., you need to strongly
consider precast pavement
If you have only 5 hrs., precast likely your best
option
The Fort Miller Co., Inc.
Benefits of Precast Pavement
Reduce construction-related traffic congestion
Longer lasting pavement repairs – Asset Preservation
40+ years
Reduced (long-term) repair costs
“Get in, get out and stay out”
“Incremental Total Replacement” – now possible
Reduces field inspection time and cost
Precast slabs – plant inspected
Pre-engineered, pre-inspected slabs result in a superior
finished pavement
The Fort Miller Co., Inc.
Benefits to Contractors
Eliminates design and submittal of fast-track concrete mix
NYSDOT requires 45 Days for approval
Fewer risks in placement
No finishing
No curing time
Immediately open to traffic
Less weather sensitive – longer construction season
Material costs known at bid time
The Fort Miller Co., Inc.
Super-Slab® Pavement BASICS
Precast Slabs – Precision Engineered, Durable
40+ yr, Cost Effective
+ Uniform Support – Super-Grading, Fully
Compacted Subgrade
+ Match Road Surface – Plane & Warped
+ Effective Load Transfer Between Slabs Dowels in Fully Grouted Dovetail Slots
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Successful Long-term Overnight Repair
15,000 Slabs = 25+ lane-miles
The Fort Miller Co., Inc.
Keys to Success
(Still More to Learn)
Good engineering
Open minds
Real partnering
Question #1:
What are the two types of concrete roadway
repair made with Super-Slab® System?
Answer:
1) Intermittent or patch repair installations
2) Continuous repair installations
Question #2:
How does Super-Slab® System accommodate
complex pavement surface geometry?
Answer:
Using a combination of planar and non-planar
slabs on a matching precision graded
subbase
Question #3:
What is the shortest work-window to be used with
Super-Slab® System?
Answer:
5 Hours – 1:00 AM to 6:00 AM
NYS Thruway Authority – I-95 New Rochelle, NY
Thank You
The Fort Miller Co., Inc.